SAP EWM Lessons Learned Case Studies From the Warehouse Floor

7/22/2019 SAP EWM Lessons Learned Case Studies From the Warehouse Floor

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[SAP EWM LESSONS LEARNED: CASE STUDIES FROM

THE WAREHOUSE FLOORChris Gregory

LogiStar Solutions


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Key Presentation Points

Learn how SCM EWM can support various business andoperational requirements, including advanced functionality

Listen to three real world EWM Case Studies across multipleindustries

Understand Best Practices and how to apply these to yourEWM implementation


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[ Who Is LogiStar?

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[ LogiStar Core Services

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Greenfield Sites

Legacy WMS Replacements

3PL Replacements/In Sourcing WM Optimizations

Upgrades

IM WM

WM EWM

Turn Key Projects

Staff Augmentation

Functional Technical

Project Management

Blueprint Services

Advisory services

Project Types Service Offering


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[ SAP EWM Functionality Overview

SAP ERP WM had evolved but did not

provide advanced features orfunctionality

SAP SCM Extended WarehouseManagement solution is an entirelydifferent platform from ERP WM

Can accommodate simple to complexwarehouses

Functionality has advanced and grownbased on additional Version Releases

Created to fill the GAP with

advanced functionality i.e. Labor Management, Slotting,

etc.

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[ SAP EWM Functionality Overview (cont)

Robust Warehouse Management System

Placement/Removal Strategies

Data Collection with SAPConsole or ITSMobile (RF)

Advanced Wave Planning

Unique Pallet ID ManagementHandling Units

Material Flow Systems (MHE Control)

Packing

Quality Inspection Engine

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[ SAP EWM Functionality Overview (cont) Warehouse Monitoring Tools / Reporting / Graphical

Cockpits

Resource Management Functionality

Physical Inventory / Cycle Counting

Cross Docking

Yard Management

Value Added Services / Kitting

Slotting

Labor Management

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[ Solution Details SAP EWM - A Complete Offering Resulting fromsolid, Continuous Investment

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Inbound Processing

ASN data receiving, validation,correction

Transportation unit mgmt.

Goods receipt

Putaway bin determination

Internal routing

Deconsolidation

Putaway

Returns / reverse logistics

Goods receipt optimization

Advanced returns mgmt.

Outbound Processing

Order deployment

Route determination

Transportation unit mgmt.

Wave management

Picking bin determination

Warehouse order creation

Work assignment

Picking, packing, staging

Loading & goods issue

Kit-to-order

Direct outbound delivery

Production supply

Storage & Operations

Rearrangement

Slotting

Inventory counts / record accuracy

Replenishment

Freight order management

Scrapping

Kit-to stock

Transportation cross docking

Pick from goods receipt/push deployment

Yard management

Task interleaving

Execution constraint mgmt.

Semi-system-guided work

Labor management

Opportunistic cross docking

Merchandise distr. X-docking

Stock-specific unit of measureCROSS

PROCESSES

CORE

P

ROCESSES

Warehouse Monitor RF / RFID enablement

Quality inspection

Import / exportintegration

EH&S integration

eSOA enablement

Migration tools

Pick by Voice

Packaging specification Batch management

Serial numbers

Catch weight

Material Flow System

Warehouse cockpit

Dock Appointment Scheduling

Integration with SAP TM

Graphical warehouse layout Transp. integration (LES)

Claims & Returns

ERP transportation integration

Multiple EAN

Cartonization

Rapid deployment solution

KPIs, Performance dashboard

SUPPORTIN

GAREAS

EWM 5.0

EWM 5.1

EWM 7.0 EWM 7.01

EWM 7.02

EWM 9.0

Source: SAP


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[ Native integration with SAP Business Suite: Comprehensive,Smooth, & Real-time Process Integration

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Order processing

Customer relationship management (CRM)

Back-order processing (global available to promise)

Advanced claims and returns management

Track and trace

Comprehensive production supply support

(process orders and crate parts)

Dangerous goods handling Storage and document printing

Compliance with import and export regulations

Customs; bonded warehouse

Advance shipping notification (ASN)

Inbound quality management

Sales and distribution

Procurement

SAP Manufacturing

SAP Environment, Health, andSafety Management

SAP Global Trade Services

Source: SAP


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[ Overview SAP EWM Customer & Market Status - StrongCustomer Growth & Implementation Momentum

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Facts and Figures

Over 200 active customers added in 2012

More than 500 distinct live/active customers

Productive use of SAP EWM in more than 20 countriesand 24 industries

Sample Customers

Live Customers and Live Sites Customer Geographical Cverage

Coca-ColaEnterprises

0

100

200

300

400

500

600

12/31/0712/31/0812/31/0912/31/1012/31/1112/31/12

Live Sites

Live

Customers

Source: SAP
http://www.dsg.dk/da/Pages/Forside.aspxhttp://www.daimler.com/dccom/home/dehttp://www.wuerth.de/web/de/awkg/index.php


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LogiStar Case Study #1

Harry & David


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[ Logistar SAP EWM Customer Case Study: Harry & David

One of the nations oldest mail order catalog companies

Full implementation of SCM EWM for two distribution facilities, replacingCatalyst and RedPrairie WMS solutions.

Design included full EWM functionality including Wave Planning, LaborManagement, Value Added Services, and Kitting.

High volume operation with over 450,000 orders per day during peakseason.

Successful go-live and stabilization in Q1 2013

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[ Harry & DavidProcess for Reviewing EWM

Provide end-to-end warehouse management capabilities for all sites and alldivisions

Provide full visibility to all materials across all locations

Close integration between EWM and Manufacturing

License plate bar coding and tracking required

Full RF capabilities Wave creation and assignment

Elimination of manual processes

Clerical

Kitting

Order close

Data entry

Improve inventory transfers between sites & plants

Improve batch control at the end customer level

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[ Harry & DavidRationale for Selecting EWM

Simplify the IT Landscape

Consolidate aging and custom applications under one platform reducingoperational risk

Reduce IT complexitySingle Platform

Reduce/eliminate MS Excel, Access and other side systems

Reduce maintenance cost of two disparate WM systems

Reduce interface complexity and maintenance cost with a tightly integratedsystem

Enhanced Capabilities

Labor Management

Full HU tracking (LPN)

Value Added Services

Slotting

Cross Docking

Yard Management

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[ Harry & DavidProject Expectations

Provide the business with the means to manufacture and fulfill orders in the

quickest, most cost effective manner

Improved customer experience through order accuracy, processing orderchanges/cancellations, order consolidation and status visibility with SAP EWM

and its tight integration to current SAP ERP.

Improved visibility

Enterprise view of orders and inventories

Inventory accuracy and management

Single system supporting standardization across facilities

Improved productivity through optimized tasks and workflow management

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[ Harry & DavidProject Expectations

Eliminate the need for:

Maintaining data in external local sources

External tools like EXCEL, ACCESS

Non-system processesEnabling the various value added warehouse andproduction activities within the WMS, eliminating manual processes andexternal databases

Gain increased capabilities for labor management including labor planningand overall labor performance

Improved dock management and carrier accountability though YardManagement

Increased system based quality management with EWM Quality InspectionEngine

Improved facility utilization with new EWM organization structure designlike PSA and Work centres for Production process, Work centres for VAS

process

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[ Harry & DavidLessons Learned

Early informational training to key users is vital for the success of the

project.

Defining reporting requirements early in Blueprint Phase

Need to have a willingness to accept change process. Without it, theproject will not be successful.

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[ Case Study #2

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Kimberly Clark


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[ LogiStar Solutions SAP EWM Case Study: Kimberly ClarkHealthcare

Why did Kimberly-Clark choose EWM

Scope of Kimberly-Clark EWM implementation

SAP EWM Landscape

SAP EWM functionalities deployed

Realized benefits of SAP EWM

Lessons Learned

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[ Kimberly Clark - A Global Health and Hygiene Leader

Well-known global brands

HUGGIES KLEENEX

SCOTT

KOTEX

PULL-UPS

DEPEND

58,000employees worldwide

$21.1 Billion in Net Sales in 2012

#1 or #2 positionin morethan 80 countries

1.3 billionconsumersuse our products daily

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[ Kimberly Clark Businesses

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Personal Care

Health Care

Consumer Tissue

K-C Professional


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[ Why SAP EWM for KIMBERLY CLARK HEALTHCARE?

1. Paper based tracking of materials led to errors and lost paper

2. Needed visibility to inbound receipts from vendors

3. Time wasted finding an empty bin for putaway

4. Time wasted finding the bin that contained the materials to pick

5. Cycle counting was a challenge

6. Regulatory requirements

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[ Project Scope

Implement EWM at a Health Care location which contained 80% of all

Health Care processes to establish global template

Use template approach to complete 18 EWM rollouts in 3 years!

EWM would manage vendor receipts, production staging, productionconfirmation, stock transfer orders, customer sales orders and physicalinventory

EWM project scope expanded to included:

Activation of batch management on selected materials

Standardize labels

Implementation of wireless mobile data collection devices

Activate gATP ARIBA ASN for top customers

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[ Integrating SAP EWM into Overall System Landscape

SAP EWM deployed as stand-alone solution

Kimberly-Clark was already running two SCM 5.1 servers; one for DP, SNP,and PPDS and another for gATP. Didnt want to upgrade existing serversto SCM 7.1.

Concerns about EWM affecting APO optimization and gATP processing

Solution Benefits:

Potential to use dedicated EWM server as a global instance

Potential growth to implement EWM across other business

Stand alone server allows more freedom for enhancement and OSSimplementation coordination

Ability to transact in EWM if ECC is down

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[ SAP EWM Functionality: Meeting KCH Needs

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Requirement Solution

Receive vendor purchase orders and inbound STOs Inbound Delivery Receipts (PRDI)

Efficient putaway and picking Process Oriented Storage Control

Production confirmation receipts & componentbackflushing

Inbound Delivery (PRDI)Outbound Delivery (PRDO)

Push product to other sites instead of responding to an

STO

Direct Outbound Delivery

Efficient material movements Handling Units

Picking for multiple customer orders Outbound Delivery (PRDO)

Wave


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[ SAP EWM Functionality: Meeting KCH Needs

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Requirement Solution

Automated replenishment Fixed Bin ReplenishmentOrder Based Replenishment

Visibility to quality Inspection Document

Centralized location for reporting EWM Warehouse Monitor

Ease of use of physical inventory Physical Inventory Document

Better management of inbound and outbound trailers Future Yard Management

Implementation

ARIBA ASN with vendors Future Implementation with ASNs

(PRDI)


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[ Realized Benefits of EWM

Standardized warehouse structure increased efficiency of putaway and

picking tasks

Visibility to the exact location of inventory

Direct Outbound Delivery functionality in EWM allowed us to free 8 hoursof resource time

MB56Batch Where Used List

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[ Kimberly Clark Healthcare: SAP EWM Lessons Learned

Dont be afraid to over communicate!!

Ensure project team includes a representative from all system touch points

ECC MM

EWM MM

PP

OD

OT

APO

gATP

PI

BI

Legacy Systems

Prioritize nice to haves versus must haves

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[ Kimberly Clark Healthcare - SAP EWM Lessons Learned

Allocate enough time in project timeline for testing and training

Treat system cutovers as dress rehearsals

Face-to-face testing cycle allowed testing cycle to stay on-track

Include COE/SME/KUT resources as part of testing phases

Background knowledge of CIF was key

Dont forget about security

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[ Case Study #3

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Bombardier


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[ LogiStar Solutions SAP EWM Customer Case Study

Global Aerospace Manufacturer

After Market Parts Distribution Operation

Converted SAP ERP WM run by 3PL to customer-owned SAP EWM facility

Big bang Full lifecycle EWM implementation approach for two facilities in

USA and Europe.

Project Scope included: Complex inbound and outbound processes

Batch Management

Serial numbers

ERP QM integration

Significant FAA documentation requirements Wave Planning

Slotting

Resource Management

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[ Key Drivers for SAP EWM

Business requirements changed over the last several years.

International and Domestic products mixes have changed

Changing Customer Requirements: More flexibility

More diverse services

Improved efficiency

The existing solution had limited functionality to meet needs

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[ Key SAP EWM Integration Points

Synchronization & Communication between EWM & ERP

Master Data

Transactional Data between EWM and ERP(Sales orders, Purchase ordersand Stock Replenishment orders)

Inventory UpdatesInventory postings

Financial IntegrationFinancial Posting for Post Goods Issue (PGI) and Post

Goods Receipt (PGR)

Other Communication to ERP or Legacy systems needed based on thescope of EWM functionality such as Environmental Health and Safety(EH&S), Billing Systems, and Global Trade Services

CIF (Core Interface) Communication exchange of data between SAP ERP

and SAP EWM ensuring Data Consistency and Integrity

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[ Key Changes

Improved process for inbound, outbound and inventory control

Heightened visibility throughout the entire warehouse 100% inventory visibility

Every Physical part movement captured in EWM with user ID, date and time

Eliminate interfaces IDOCs and external Data bases

Radio Frequency Technology

Minimize Waste Duplicate processes

Manual data entries, (minimize errors)

Duplicate auditing

Reduce paperwork

Wave Management

Consolidation of customer orders allowing financial benefits for customers Reduce delays in processing , AOG orders ship < 2 hrs

Real time status improves accuracy

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[ Solution Benefits

Improved material handling processes

Reduction in manual entries and subsequent errors

Eliminate external databases and interfaces

Eliminate dual processing and auditing

Eliminate paper, fully RF based processing

Reduce delays in processing

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[ Solution Benefits

Reprint capabilities, mobile printing

Real time transactions results in improved accuracy

Wave management allows for optimized work flow

Customer order consolidation allows internal financial benefits and for thecustomer

Reduction in manual entries and subsequent errors

Standardized support and development team

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[ Key Lessons Learned

Utilize standard functionality as much as possible

EWM offers comprehensive functionality to fit many complex processes, its

important to fully understand the depth of functionality

Invest in design prototypes early on in the project timeline

Demos functionality to key users to help drive key decisions

Business and IT participation / ownership / engagement

Key decision makers must fully support project objectives

Power Users to be on boarded from blueprint onward

Business units outside of the Warehouse need to be integrated into theBlueprint

Post go-live on-site support can not be underestimated in terms of effort or

duration

An overall Business Change Lead to be assigned from the beginning

Roles and responsibilities (Business and IT) must be clearly defined withinthe project team

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[ Lessons Learned (Continued)

Cutover plan can not be too detailed and must include contingency

Communication and planning for all areas can not be underestimated (Businessplan, IT plan)

Contingency planning is critical (what if scenarios)`

Testing and dry-runs need to be comprehensive and long enough

Do not underestimate the number of business areas and business users that will

require testing

Need to test with realistic volumes (data, transactions, users etc)

Need to ensure the time to consolidate training & practice in the new systemwith the new processes and tools

Day In The Life testing and simulation

Pay attention to the small stuff during dry-runs and go-live scenarios, the impactof small variances will be magnified with go-live volumes

Dont assume the basics will be acceptable without validation

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Best Practices

Leverage standard EWM functionality where possible -- solution offers

comprehensive functionality

Involve key users across all solution touch points early in the project toincrease knowledge base and solution ownership

Embrace Change and have established systems to effectively manage changeacross the organization and your customers

Onsite face-to-face testing cycles combined with realistic test data(transactions, volume, users) significantly improves results

Variety of implementation methodologies are available (ASAP, Agile,Prototyping)use approach that fits your project best

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[ Q&A

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For more information contactChris Gregory

[email protected]

www.Logi-star.com
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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SAP EWM Lessons Learned Case Studies From the Warehouse Floor